I want to build a large-scale compound feed mill with a capacity of more than 100 t/h. Can you show me an example?

The following shows you a large-scale compound feed mill project with an annual output of 300,000 tons, with an output of 125t/h. The compound feed factory is mainly used to process chicken feed, goose feed, pig feed and aquatic feed. The aquatic feed produced by this compound feed mill project includes grass carp feed, carp feed and shrimp feed, and does not use the puffing process.

In addition, the compound feed factory contains 4 animal feed pellet production lines, of which three livestock and poultry feed lines process pellet feed and powder feed at the same time.

With the development and progress of society and the improvement of people's living standards, especially the acceleration of the pace of life, people's demand for the variety structure of poultry and meat products has also undergone great changes. Ecological, organic, safe, nutritious and delicious meat products It is becoming more and more popular among the masses.

The implementation of this compound feed mill project will not only promote the development of the breeding industry, but also promote the development of related auxiliary industries. Such as promoting the development of feed processing industry, packaging materials, material circulation, etc.

This project uses local breeding resources for processing, reducing transportation costs and improving the quality of raw materials. The products will be mainly sold to the Asian market. After the implementation of this compound feed mill project, its economic and social benefits are very significant.

The customer's animal feed company was founded in 1999 and is mainly engaged in feed processing, production and operation. The customer owns a feed factory with a production capacity of 180,000 t/a of livestock, poultry, and aquatic feed.

• Project investment: US$10.59 million. 
• Occupied area: This 125t/h compound feed mill project covers an area of 60 acres, with a construction area of 41,770 square meters.
• Labor capacity: 80 people.
• Working system: 300 days of operation per year, one shift, 8 hours of work.
• Production scale: The construction area is 41,770 square meters, mainly including a comprehensive building of 13,000 square meters, a workshop of 12,440 square meters, a warehouse of 10,010 square meters, an apartment, a guard room of 6,320 square meters, and a supporting weighing room, etc. It is planned to install 4 mechanized feed production lines. Produces 300,000 tons of high-end, high-quality livestock, poultry, and aquatic feed.
• Annual electricity consumption: The electricity load of this compound feed mill project consists of production equipment, public works and domestic electricity. The total electricity consumption is about 7.5 million kw·h/a.
• Natural gas supply: Set up a boiler room and two 3t/h gas boilers (one for use and one for backup). The annual natural gas consumption is about 300,000 m3, which is supplied by the municipal natural gas pipeline network.

Construction Content

• Workshop: Located in the middle of the 125t/h compound feed mill, 6F, brick-concrete, covering an area of 900m2 (30m*30m), with a construction area of about 5400m2, with 3 livestock and poultry feed production lines and 1 aquatic feed production line, including screening and magnetic separation, crushing, and mixing , granulation, screening and other processes. (Part of the 6F area is used for feed research and development and testing.)
• Auxiliary workshop: Located on the southwest side of the feed mill factory, 2F steel structure (part of 4F), construction area of about 5504m2, (86m*32m), temporarily vacant.
• Comprehensive building: Located on the north side of the factory, 4F, mainly used for offices.
• Staff dormitory: Located on the south side of the complex building, 4F, brick-concrete structure, construction area 3840m2, provides employees with dining places and living, 1F has a canteen.
• Raw material warehouse: Located on the north side of the compound feed mill factory, 2F, steel structure, with an area of about 10200m2, used for the storage of raw materials such as soybean meal, wheat, sub-flour, bran, rapeseed meal, fish meal and so on.
• Finished product warehouse: Located on the north side of the factory, 2F, steel structure, with an area of about 6720m2, used for storage of finished feed products.
• Soft water system: The soft water system provides boiler soft water for natural gas steam boilers. The water production process used is ion exchange. It adopts the ion exchange principle and the treatment scale is 4m3/h.

Product solutions of 125 t/h compound feed mill

• "Compound Feed for Piglets and Growing and Finishing Pigs" (GB/T 5915-1993)
• "Compound feed for laying hens, laying hens, and broiler chickens" (GB/T 5916-2004)
• "Compound Feed for Gilts, Pregnant Pigs, Lactating Sows, and Breeding Boars" (LS/T 3401-1992)
• "Compound Feed for Growing Ducks, Laying Ducks, and Meat Ducks" (LS/T 3410-1996)
• ...

• "Compound Feed for Carp" (SC/T 1026-2002)
• "Grass Carp Compound Feed" (SC/T1024-2002)
• "Compound Feed for Crucian Carp" (SC/T 1076-2004)
• "General Technical Requirements for Compound Feeds for Fishing" (SC/T1077-2004)
• "Shrimp Compound Feed" (SC/T2002-2002)
• "Compound Feed for Black Carp" (SC/T1073-2004)
• ...

Raw materials consumption in 125t/h compound feed mill

Feed equipment need in 125 t/h compound feed mill

• Each poultry and livestock feed production line is equipped with a crusher, a mixer, an animal livestock feed pellet machine, and a screening machine.
• One of the animal feed production lines is equipped with an additional crusher (depending on the actual production, it may be in production). Pelletization is required after granulation).
• The crushing capacity of the crusher on a single livestock and poultry feed production line is 40t/h, and the mixing capacity of the mixer is 40t/h. About 75% requires granulation.
• The granulating capacity of the animal feed granulator is 30t/h. h, the screening capacity of the screening machine is 30t/h, about 60% of the granules need to be broken after granulation, and the crushing capacity of the crusher is 18t/h.

Calculating the annual working hours as 2400 hours, the annual crushing capacity of the crusher on a single livestock and poultry feed production line is 96,000t, the annual mixing capacity of the mixer is 96,000t/h, the annual granulating capacity of the animal feed pellet making machine is 72,000t, and the annual screening capacity of the screening machine is 72,000t, the annual crushing capacity of the crusher is 43,200t, and the three livestock and poultry production lines can meet the production capacity of 270,000 tons of livestock and poultry feed.

• The aquatic fish feed production line is equipped with 2 mixers, 1 pulverizer, 1 vertical twin-shaft pulverizer, 1 fish feed pellet machine, and 1 screening machine.
• The pulverizer has a crushing capacity of 13t/h. The crushing capacity of the vertical twin-shaft pulverizer machine is 13t/h, the mixing capacity of the mixer is 13t/h, about 80% requires granulation, the granulating capacity of the fish feed pellet mill is 10t/h, and the screening capacity of the screening machine is 10t/h.
• If the annual working time is 2400 hours, then the annual crushing capacity of the crusher on a single livestock and poultry feed production line is 31200t, the annual crushing capacity of the vertical double-shaft crusher is 31200t, the annual mixing capacity of the mixer is 31200t/h, and the annual production capacity of the sinking fish feed machine is 31200t.

Auxiliary facilities of 125 t/h compound feed mill

Public works

The water used in the factory comes from the municipal water supply network for production and domestic use, which can meet the needs of this 125t/h compound feed mill project.

Domestic water

There are 80 employees. There is a canteen and accommodation in the factory. The water consumption for employees is calculated as 120L/person·d, and the water consumption in the canteen is calculated as 25L/person·meal. The domestic water consumption is 11.6m3/d, that is, 3480m3/a.

Domestic sewage generated amount is calculated based on 80% of the water consumption, then the domestic sewage production volume is 9.28m3/d, that is, 2784m3/a. After being pre-treated by grease traps and septic tanks, domestic sewage enters the sewage treatment plant through the municipal sewage pipe network for treatment.

The 125t/h compound feed mill project is equipped with a 3t/h gas boiler, the steam supply is 3t/h, the boiler operating time is calculated as 1350h/a, the steam generated by the boiler is used for direct heating, and direct heating consumes steam. This evaluation is based on the total amount of steam generated.

Consumption calculation, steam production is 13.5t/d, 4050t/a. Soft water needs to be used when boiler water is used. The soft water production process is ion exchange resin method. The treatment scale is 4m3/h. The preparation rate is calculated as 75%.

When preparing boiler soft water required amount of tap water is 5400t/a, and the amount of concentrated water produced is 1350t/a. This part of the concentrated water is mainly clean sewage with high salt content, which is directly discharged into the sewage treatment plant for treatment.

General layout

Combined with the existing site conditions, the floor plan of the 125t/h compound feed mill is designed with the best aniaml feed production processes (logistics, people flow, information flow, energy flow) and production process engineering.

The overall layout emphasizes the rationality of logistics and reduces the return, crossover, and round-trip of logistics. Wait for efficient handling; reduce inventory and work-in-progress, shorten stagnation and waiting for materials; choose appropriate loading and unloading handling methods and machinery.

The overall layout follows the principles of intensive and compact land use, reasonable functional zoning, smooth process flow, and short transportation lines.

The building layout is combined with the shape of the land, fully considering the requirements for sunlight, ventilation, and fire protection, and at the same time, it is coordinated with the surrounding environment.

When laying out the general layout, strictly follow the relevant provisions of the "Code for Fire Protection Design of Buildings" .

125 t/h compound feed mill process design

01

Raw material receiving (unloading, feeding):

Incoming bulk corn and soybean meal are unloaded in the unloading shed. After being unloaded into the grain pit, they are lifted into the silo by the elevator for use. There are four 1500t corn silos and six 250t soybean meal silos.

During production, the silo is transported and lifted to the production workshop by a bucket elevator. Bags of wheat, bran and other auxiliary materials are stored in the warehouse after incoming materials.

During production, bagged wheat, bran, sub-flour, rapeseed meal, cottonseed meal and other auxiliary materials pass through independent feeding (flip-type closed air feeding port) receiving systems. After receiving the materials, they are transported to the screening process by pipelines.

Due to the nature of the work, , personnel ratio and equipment settings, and the receipt of raw and auxiliary materials is not carried out at the same time.

02

Impurity removal and crushing (sieving, magnetic separation, crushing):

During production, corn kernels and soybean meal are transported to the cylindrical primary cleaning screen and permanent magnetic screen in the production workshop respectively by a closed conveying system, and auxiliary materials such as wheat, bran, secondary flour, rapeseed meal, cotton meal, etc. are transported through scraper conveyors and elevators. Transported to cylindrical primary cleaning screen and permanent magnetic screen.

After the initial cylindrical cleaning screen and permanent magnetic screen remove impurities, it enters the crusher. The screening is mainly to remove sand, gravel, plastic and other impurities in the raw materials. The magnetic separation is mainly to remove some magnetic impurities in the raw materials and protect the safety of equipment and feed.

After screening and magnetic separation, the raw materials enter the crusher for crushing and are then lifted to the batching bin by bucket elevators to wait for batching.

03

Ingredients:

Multi-bin digital batching is used, and five closed batching bins are set up. The total capacity of the batching bins is about 750 cubic meters. The measured materials are grouped according to their physical characteristics or weighing range, and each group is equipped with a corresponding measuring device.

04

Mixing:

Continuous mixing process is used in this 125t/h compound feed mill. The continuous mixing process is to continuously measure various feed components at the same time and mix them into a stream containing various components in a certain proportion according to customer and product requirements. When the stream enters the mixer, it is continuously Mix to form a uniform stream.

The mixed finished powder can be granulated as needed, or can be directly packed into the finished product warehouse or packed into a bulk finished product warehouse and loaded on a bulk truck for shipment.

05

Granulation:

The materials mixed by the mixer enter the animal livestock poultry feed pellet machine through the feeder, add steam (the steam is provided by the natural gas boiler and transported through the steam pipeline) for high-temperature quenching and tempering (the temperature is about 60~80°C), and then go through the pressure of the animal feed pelletizer. Molding rollers squeeze out pelletized feed.

06

Cooling:

After pelleting, the pellets have a large moisture content and a high temperature. Under these conditions, the pellet feed is prone to deformation, breakage, mildew and adhesion. Use a cooler (air cooling) to cool down and air-dry the materials.

07

Crumbling:

After the granular feed is cooled, part of the feed is sent to the crusher to break the long pellets into products that meet the product specifications according to the customer's pellet size requirements.

08

Screening, inspection and packaging:

The cooled granular feed or cumbled feed is sorted through a grading screen, and the finished products are inspected. Those that pass the inspection are automatically packaged by the packaging machine, and then sent to the finished product warehouse for storage. Unqualified feed pellets are re-pelletized.

09

Inspection:

For products, inspection equipment such as near-infrared spectrometers can be used to measure conventional indicators such as protein, fat, moisture, ash, and cellulose in feed. At the same time, amino acids, fatty acids, peroxide values, acid values, and biogenic amines in feed can also be measured.

The above is an example of a 125t/h compound feed mill cited by RICHI.

It is worth mentioning that in this large compound feed mill project, RICHI provided a complete set of animal feed mill machine for the chicken feed production line and aquatic feed production line. Pig feed and goose feed production lines are provided by two other manufacturers from Europe.

As I believe you can see from the above, if you want to start a large 125t/h compound feed mill, our animal feed solutions help you produce top quality feed and to make economical use of your raw materials and energy. As a technology partner with long-lasting experience in the industry, we support you in every aspect of the production of reliable animal feed.